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Lincoln Electric 400 CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)

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CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)

TROUBLESHOOTING & REPAIR

F-23 F-23

VANTAGE® 400

REASSEMBLY PROCEDURE

1. Install components in reverse order of removal.

2. Be sure components align correctly.

3. Reconnect battery and replace battery door.

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Contents

Main VANTAGE400 SVM182-A April, 2011 SERVICE MANUAL i i WARNING ELECTRIC AND MAGNETIC FIELDS may be dangerous ii ii FUMES AND GASES can be dangerous. ARC RAYS can burn. ELECTRIC SHOCK can kill. VANTAGE 400 iii iii FOR ELECTRICALLY powered equipment. CYLINDER may explode if damaged. WELDING and CUTTING SPARKS can cause fire or explosion. Refer to http://www.lincolnelectric.com/safety for additional safety information. iv iv PRCAUTIONS DE SRET PRCAUTIONS DE SRET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR - MASTER TABLE OF CONTENTS FOR ALL SECTIONS - TABLE OF CONTENTS - INSTALLATION SECTION TECHNICAL SPECIFICATIONS - VANTAGE 400 (K2410-1) (K2410-2) RATED OUTPUT @ 104 F (40 C) - WELDER MACHINE SPECIFICATIONS PHYSICAL DIMENSIONS ENGINE RATED OUTPUT @ 104 F (40 C).- GENERATOR SAFETY PRECAUTIONS Only qualified personnel should install, use, or service this equipment. See additional warning information at front of this operators manual. VRD (VOLTAGE REDUCTION DEVICE) LOCATION AND VENTILATION HIGH ALTITUDE OPERATION HIGH TEMPERATURE OPERATION COLD WEATHER STARTING: TOWING VEHICLE MOUNTING OIL FUEL ENGINE COOLING SYSTEM BATTERY CONNECTION MUFFLER OUTLET PIPE ELECTRICAL CONNECTIONS MACHINE GROUNDING WELDING TERMINALS WELDING OUTPUT CABLES TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES STANDBY POWER CONNECTIONS AUXILIARY POWER RECEPTACLES CONNECTION OF VANTAGE 400 TO PREMISES CONNECTION OF LINCOLN ELEC- TRIC WIRE FEEDERS CONNECTION OF LN-7 OR LN-8 TO THE VANTAGE 400 CONNECTION OF LN-15 TO THE VAN- TAGE 400 CONNECTION OF SPOOL GUN (K487-25) AND COBRAMATIC TO VANTAGE 400 CONNECTION OF PRINCE XL SPOOL GUN TO THE VANTAGE 400 TABLE OF CONTENTS - OPERATION SECTION SAFETY PRECAUTIONS GENERAL DESCRIPTION FOR AUXILIARY POWER: ENGINE OPERATION ADD FUEL DIESEL FUEL ONLY WELDING CONTROLS 4. ARC CONTROL 5. WELD OUTPUT TERMINALS WITH FLANGE NUT- 6. GROUND STUD- 7. 14-PIN CONNECTOR- 8. 6-PIN CONNECTOR- ENGINE CONTROLS: 12. RUN/STOP SWITCH 13. GLOW PLUG PUSH BUTTON 14. START PUSH BUTTON 15. IDLER SWITCH WELDER OPERATION STOPPING THE ENGINE TIG WELDING TYPICAL CURRENT RANGES (1) FOR TUNGSTEN ELECTRODES AUXILIARY POWER: PLUS OR OR ARC GOUGING WIRE WELDING-CV TABLE OF CONTENTS - ACCESSORIES SECTION FIELD INSTALLED OPTIONS / ACCES- SORIES WIRE FEEDER OPTIONS TIG OPTIONS PLASMACUTTING C-3 C-3 Page Page C-6 C-6 Page Page TABLE OF CONTENTS - MAINTENANCE SECTION SAFETY PRECAUTIONS ------------------------------------------------------------ Routine Maintenance ENGINE SERVICE ENGINE OIL CHANGE OIL FILTER CHANGE AIR CLEANER Page COOLING SYSTEM HOT COOLANT TIGHTENING THE FAN BELT FUEL BLEEDING THE FUEL SYSTEM FUEL FILTER ENGINE ADJUSTMENT BATTERY MAINTENANCE OVERSPEED IS HAZARDOUS CLEANING THE BATTERY CHECKING THE ELECTROLYTE LEVEL WELDER / GENERATOR MAINTENANCE GFCI RECEPTACLE TESTING AND RESET- TING PROCEDURE Page TABLE OF CONTENTS-THEORY OF OPERATION SECTION E-1 E-1 ENGINE + ROTOR GENERAL DESCRIPTION BATTERY, ENGINE, ROTOR, STATOR, PULL COIL BOARD AND PERIPHERAL BOARD ENGINE PROTECTION E-3 E-3 FIGURE E.3 WELD WINDINGS, RECTIFIER, CHOPPER MODULES & FEEDBACK ENGINE WELD WINDINGS, RECTIFIER, POWER MODULES AND FEEDBACK E-4 E-4 FIGURE E.4 WELD CONTROL BOARD ENGINE + WELD CONTROL BOARD INSULATED GATE BIPOLAR TRANSISTOR (IGBT) OPERATION PULSE WIDTH MODULATION CHOPPER TECHNOLOGY FUNDAMENTALS Page TABLE OF CONTENTS - TROUBLESHOOTING & REPAIR HOW TO USE TROUBLESHOOTING GUIDE PC BOARD TROUBLESHOOTING PROCEDURES Page Page Page Page FUNCTION PROBLEMS Page Page Page WELDING PROBLEMS Page Page Page Page Page Page Page Page CASE COVER REMOVAL AND REPLACEMENT PROCEDURE Page CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED) REASSEMBLY PROCEDURE Page CHOPPER MODULE CAPACITOR DISCHARGE PROCEDURE CHOPPER MODULE CAPACITOR DISCHARGE PROCEDURE (CONTINUED) INSULATED GLOVES INSULATED PLIERS ELECTRIC SHOCK DISCHARGE PROCEDURE FUEL SHUTDOWN SOLENOID TEST SHUTDOWN SOLENOID IDLE SOLENOID FUEL SHUTDOWN SOLENOID TEST (CONTINUED) ENGINE THROTTLE ADJUSTMENT TEST STROBE TACH MARK SHUTDOWN SOLENOID IDLE SOLENOID LOW SPEED ADJ. DO NOT TOUCH FOR LOW SPEED HIGH SPEED ADJ. Page IDLER SOLENOID TEST BLACK RED P-55 J-55 1 226 3 IDLE SOLENOID CONNECTOR (LEAD ENTRY VIEW) ENGINE ALTERNATOR TEST ENGINE ALTERNATOR TEST (CONTINUED) BRUSH AND SLIP RING SERVICE PROCEDURE BRUSH AND SLIP RING SERVICE PROCEDURE (CONTINUED) ROTOR RESISTANCE AND GROUND TEST (STATIC) BRUSHES SLIP RINGS #200A #200B #201 - + ROTOR RESISTANCE AND GROUND TEST (STATIC) (CONTINUED) ROTOR RESISTANCE AND GROUND TEST (DYNAMIC) (Also referred to as flying resistance test) ROTOR RESISTANCE AND GROUND TEST (DYNAMIC) (CONTINUED) ROTOR VOLTAGE TEST BRUSHES SLIP RINGS #200A #200B #201 - + ROTOR VOLTAGE TEST (CONTINUED) Page FLASHING VOLTAGE TEST (Engine Not Running) Page FLASHING VOLTAGE TEST (CONTINUED) Page STATOR VOLTAGE TESTS AMPHENOL 1 KEY Page Page STATOR SHORT CIRCUIT & GROUND TEST STATOR SHORT CIRCUIT & GROUND TEST (CONTINUED) OUTPUT RECTIFIER BRIDGE TEST Page CHOPPER BOARD OUTPUT RECTIFIER BRIDGE TEST (CONTINUED) OR Rectifier Terminal Connections CHOPPER MODULE FUNCTION TEST B1 B2 B3 B6 B4 B5 CHOPPER MODULE FUNCTION TEST (CONTINUED) TEST PROCEDURE (CONTINUED) Page CHOPPER MODULE RESISTANCE TEST Page CHOPPER MODULE RESISTANCE TEST (CONTINUED) Chopper Terminal Connections Page WELD CONTROL BOARD PWM GATE SIGNAL TEST WELD CONTROL BOARD PWM GATE SIGNAL TEST (CONTINUED) WELD CONTROL FEEDBACK TEST Page WELD CONTROL FEEDBACK TEST (CONTINUED) Page Page CONTROL POTENTIOMETER AND MODE SWITCH RESISTANCE TEST CONTROL POTENTIOMETER AND MODE RESISTANCE TEST POT/MODE SWITCH RESISTANCE TEST Page REMOTE RECEPTACLE RESISTANCE TEST REMOTE RECEPTACLE RESISTANCE TEST (CONTINUED) AMPHENOL 1 E C D A B LKJ MN FGH AMPHENOL RESISTANCE TEST HIGH IDLE NO LOAD MAX CONTROL POT - HIGH IDLE - NO LOAD MACHINE LOADED TO 300 AMPS AT 27 VOLTS NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (WIRE CV TAP) MAX CONTROL POT - HIGH IDLE - NO LOAD NORMAL CIRCUIT VOLTAGE WAVEFORM (WIRE CV) MACHINE LOADED TO 300 AMPS AT 28 VOLTS Page REMOVAL PROCEDURE REPLACEMENT PROCEDURE Replacing the Output Rectifier Page CHOPPER MODULE REMOVAL AND REPLACEMENT CHOPPER MODULE REMOVAL AND REPLACEMENT (CONTINUED) PROCEDURE B4 B5 REMOVAL CHOPPER MODULE REMOVAL AND REPLACEMENT (CONTINUED) REPLACEMENT Page Page { Page Page Page Page { STATOR REMOVAL PROCEDURE FLEX PLATE BLOWER SEGMENT (4) ROTOR ROTOR REMOVAL PROCEDURE REASSEMBLY NOTES Replacing the Rotor RETEST AFTER REPAIR ENGINE OUTPUT WELDER DC (STICK) OUTPUT (ARC control @ -10) WELDER CV (WIRE) OUTPUT (ARC Control @ +10) TOUCH START TIG (ARC Control @ +10) TABLE OF CONTENTS - DIAGRAM SECTION * NOTE: ELECTRICAL DIAGRAMS WIRING DIAGRAM - COMPLETE MACHINE - (G5481) ET E F WI ELECTRICAL DIAGRAMS SCHEMATIC - COMPLETE MACHINE - (G5597 PAGE 1) 75A & 76 on Leads Ferrite ELECTRICAL DIAGRAMS SCHEMATIC - COMPLETE MACHINE - (G5597 PAGE 2) NOT ALL CIRCUITS ARE USED ALL THE TIME. CUI L CIR Page Page Page Page Page Page Page Page ELECTRICAL DIAGRAMS ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY - BY PASS / STABILIZER PC BOARD (L10121-3) ATI NFORM I